Method and apparatus for separating a pane of brittle material from a moving ribbon of the material

ABSTRACT

A pane is separated from a moving ribbon of brittle material by restraining the ribbon upstream of a score line prior to separating the pane. The ribbon is restrained by selectively contacting a first side and a second side of the ribbon in one of an opposite, overlapping or offset relation. The ribbon can be restrained prior to, substantially simultaneous with or subsequent to forming the score line. The restrained status of the ribbon is maintained during and immediately after separation of the pane from the ribbon, thereby reducing the introduction of a disturbance or bending moment into the upstream ribbon.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to separating a pane of a brittle materialfrom a moving ribbon of the material, and in one configuration, toseparating panes of glass from a moving ribbon of glass, while reducingthe introduction of disturbances into the upstream ribbon.

2. Description of Related Art

Specialized glasses have found increased applicability, includingsubstrates, in the manufacture of display devices. For example, liquidcrystal displays (LCDs) have become increasingly popular for displayinginformation in calculators, watches, video games, audio and videoequipment, portable computers and even car dashboards. The improvingquality and size of LCDs has made the LCDs an attractive alternative tocathode ray tubes (CRTs) which are traditionally used in television setsand desktop computer displays. In addition, other flat panel display(FPD) types, such as plasma displays (PDs), field emission displays(FEDs) and organic light-emitting polymer displays (OLEDs) are beingdeveloped as alternatives to LCDs. Thin film transistor liquid crystaldisplays (TFT-LCD) are used in notebook computers, flat panel desktopmonitors, LCD televisions, and Internet and communication devices, toname only a few. It is increasingly useful to incorporate electroniccomponents onto a glass sheet (glass substrate) used in the displaydevice. Some display devices such as TFT-LCD panels and OLED panels aremade directly on flat glass sheets. For example, the transistors arearranged in a patterned array and are driven by peripheral circuitry toprovide (switch on) desired voltages to orient the molecules of the LCmaterial in the desired manner.

In-plane stress (and resulting strain) can result in a variation of thealignment of the transistors and the pixels. This can result indistortion in the display panel. As such, in LCD and other glass displayapplications, it is exceedingly beneficial to provide glass (substrates)that are within acceptable tolerances for distortion.

Flat panel display manufacturers are finding that demands for largerdisplay sizes and the economies of scale are driving manufacturingprocesses to larger size pieces of glass. Industry standards haveevolved from Gen III (550 mm×650 mm), Gen III.5 (600 mm×720 mm), and GenIV (1,000 mm×1,000 mm) sizes and larger. As the desired size of theglass pieces increases, the difficulty of the production and handlingincreases.

The manufacturing of the glass used as the substrate is extremelycomplex. The drawdown sheet or fusion process, described in U.S. Pat.No. 3,338,696 (Dockerty) and U.S. Pat. No. 3,682,609 (Dockerty), hereinincorporated by reference, is one of the few processes capable ofdelivering the glass without requiring costly post forming finishingoperations such as lapping and polishing.

However, the fusion process requires the separation and removal of panesfrom a continuously moving ribbon of glass. Traditionally, theseparation of the panes has been performed by forming a separation linein the ribbon of glass. Then a vacuum cup array is attached to the glassbelow the score line and the portion of the ribbon below the score lineis rotated less than 15° to cause the glass to break at the score lineand thus form the desired glass pane. This breaking produces a newlyformed leading edge on the moving ribbon and a newly formed trailingedge on the glass pane.

However, this exertion of such a large bending moment on the ribbon,imparts significant potential energy to the ribbon, particularly uponthe snapping of the pane from the ribbon. Introduction of this energy(and mechanical disturbance) into the upstream ribbon can lead toundesirable characteristics in subsequent glass panes.

Therefore, there is a need to provide for the separation of a pane froma continuously moving ribbon of brittle material, while reducingimparted disturbances which can propagate upstream along the ribbon. Theneed also exists for increasing control over the crack propagation usedto separate a pane from the ribbon.

BRIEF SUMMARY OF THE INVENTION

The present system provides for the repeatable and uniform separation ofa pane of brittle material from a continuously moving ribbon of thebrittle material, while reducing the introduction of disturbances intothe upstream ribbon.

In selected configurations, the system provides for the separation of apane of glass from a continuously moving ribbon of glass. For purposesof description, the following discussion is set forth in terms of glassmanufacturing. However, it is understood the invention as defined andset forth in the appended claims is not so limited, except for thoseclaims which specify the brittle material is glass.

In the fusion glass formation process, a glass ribbon transitions from aliquid state to a downstream solid state. The introduction ofdisturbances into the glass in the visco-elastic region of the glass canresult in undesired nonuniformity or stresses in the resulting solidstate glass. Traditionally, the separation of a pane from the ribbonintroduced significant energy in the form of a vibration, wave ordistortion to the solid portion of the ribbon. Such distortion migratesupstream into the visco-elastic region of the ribbon. The distortion canintroduce nonuniformity and nonlinearity in an uncontrolled manner, andcan decrease the quality of the resulting panes.

In the present system, the ribbon is restrained upstream of a score lineprior to separating the pane from the ribbon. The restraint of theribbon can be accomplished by contacts upstream of the score line on thefirst side and the second side of the ribbon, wherein the contacts areeither opposite, overlapping or offset. The restraint can be prior to,substantially simultaneous with or subsequent to forming the score linein the ribbon. The restraint of the ribbon is selected to facilitateseparation of a pane from the ribbon and minimize or reduce theintroduction of a disturbance or bending moment into the upstreamribbon.

The present system separates the pane from the ribbon and reduces thepropagation of disturbances upstream in the ribbon by contactingopposing sides of the ribbon with a pair of opposing bars, wherein thebars move with the ribbon, thereby restraining a portion of the ribbonupstream of a score line. A downstream press bar contacts the ribbondownstream of a score line to separate the pane from the ribbon alongthe score line, while the ribbon is temporarily restrained upstream ofthe separation line.

Additional features and advantages of the invention are set forth in thedetailed description which follows, and in part will be readily apparentto those skilled in the art from that description or recognized bypracticing the invention as described herein.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary of theinvention, and are intended to provide an overview or framework forunderstanding the nature and character of the invention as claimedbelow. Also, the above listed aspects of the invention, as well as thepreferred and other embodiments of the invention discussed and claimedbelow, can be used separately or in any and all combinations.

The accompanying drawings are included to provide a furtherunderstanding of the invention, and are incorporated in and constitute apart of this specification. The drawings illustrate various embodimentsof the invention, and together with the description serve to explain theprinciples and operation of the invention. It should be noted that thevarious features illustrated in the figures are not necessarily drawn toscale. In fact, the dimensions may be arbitrarily increased or decreasedfor clarity of discussion.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a schematic view of a fusion glass fabrication apparatus.

FIG. 2 is a front elevational schematic view of the ribbon extendingfrom a fusion glass fabrication apparatus.

FIG. 3 is a side elevational schematic view of the ribbon with theupstream press bar and an offset upstream backing bar in a retractedposition.

FIG. 4 is a side elevational schematic view of the ribbon with theupstream press bar opposite upstream backing bar in a retractedposition.

FIG. 5 is a side elevational schematic view of the ribbon with anoverlapping upstream press bar and the upstream backing bar in aretracted position.

FIGS. 6 a-6 d are side elevational schematic views of a firstconfiguration for the separation of a pane from the ribbon.

FIGS. 7 a-7 f are side elevational schematic views of a secondconfiguration for the separation of a pane from the ribbon.

FIGS. 8 a-8 f are side elevational schematic views of a thirdconfiguration for the separation of a pane from the ribbon.

FIGS. 9 a-9 f are side elevational schematic views of a fourthconfiguration for the separation of a pane from the ribbon.

FIGS. 10 a-10 d are side elevational schematic views of the contactsurface of the bars.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, for purposes of explanation andnot limitation, example embodiments disclosing specific details are setforth in order to provide a thorough understanding of the presentinvention. However, it will be apparent to one having ordinary skill inthe art having had the benefit of the present disclosure, that thepresent invention can be practiced in other embodiments that depart fromthe specific details disclosed herein. Moreover, descriptions ofwell-known devices, methods and materials are omitted so as not toobscure the description of the present invention.

The present invention relates to the separation of a pane of brittlematerial from a moving ribbon of the material, wherein selectedconfigurations reduce separation induced upstream disturbances to theribbon. For purposes of description, the present invention is set forthas separating glass panes from a moving ribbon of glass.

FIG. 1 is a schematic diagram of glass fabrication apparatus 10 of thetype typically used in the fusion process. Apparatus 10 includes formingisopipe 12, which receives molten glass (not shown) in cavity 11. Themolten glass flows over the upper edges of cavity 11 and descends alongthe outer sides of isopipe 12 to root 14 to form ribbon of glass 20.Ribbon of glass 20, after leaving root 14, traverses fixed edge rollers16. Ribbon 20 of brittle material is thus formed and has a lengthextending from root 14 to terminal free end 22. As glass ribbon 20travels down from isopipe 12, the ribbon changes from a supple 50millimeter thick liquid form at, for example, root 14 to a stiff glassribbon of approximately 0.03 mm to 2.0 mm thickness at terminal end 22.

Such draw down sheet or fusion processes, are described in U.S. Pat. No.3,338,696 (Dockerty) and U.S. Pat. No. 3,682,609 (Dockerty), hereinincorporated by reference. The details are omitted so as to not obscurethe description of the example embodiments. It is noted, however, thatother types of glass fabrication apparatus can be used in conjunctionwith the invention. For those skilled in the art of glass forming, it isknown that there are multiple methods to achieve such a structure, suchas laminated down draw, slot draw and laminated fusion processes.

For purposes of definition and as best shown in FIG. 3, as ribbon 20descends from root 14, the ribbon travels at a velocity vector Vdescribing movement of the ribbon and forms a generally flatconfiguration having a generally planar first side 32 and a generallyplanar second side 34. In certain configurations, ribbon 20 includeslateral beads or bulbous portions 36 (shown in FIG. 2) which are sizedfor engagement by fixed rollers 16 or control surfaces during travel ofthe ribbon from isopipe 12. With respect to ribbon 20, the terms“opposed” or “opposing” mean the contact on both first side 32 andsecond side 34 of the ribbon.

Depending upon the stage or operation within the sequence, the term“upstream” means between the intended location of a score line 26 (orthe actual location of the score line) and root 14. The term“downstream” means between the intended location of score line 26 (orthe actual location of the score line) and the terminal end 22 of ribbon20. Other uses of the terms upstream and downstream shall refer to thespecific location of interest, and mean toward root 14 or towardterminal end 22 of ribbon 20, respectively.

The separation of a pane 24 from ribbon 20 occurs within a givendistance range from root 14. That is, under constant operatingparameters, the glass ribbon 20 reaches a generally predetermined solidstate at a generally constant distance from the root 14, and is thusamenable to separation. The separation of pane 24 from ribbon 20 occursalong score line 26 formed in at least one side of the ribbon.

As discussed above in the Summary of the Invention, the presentinvention is directed at reducing the levels of undesirable distortionexhibited when panes 24 or substrates are flattened by providing for therepeatable and uniform separation of a pane of brittle material from acontinuously moving ribbon 20 of the brittle material, while reducingthe introduction of disturbances into the upstream ribbon.

The present apparatus includes upstream press bar 60 (FIG. 3) forengaging first side 32 of ribbon 20 and upstream backing bar 80 forengaging second side 34 of the ribbon. Each of the upstream press bar 60and upstream backing bar 80 contact ribbon 20 upstream of score line 26to locally restrain the ribbon during and after separation of pane 24.

As seen in FIGS. 6-9, in further configurations, downstream press bar70, secondary upstream backing bar 90 and downstream backing bar 100 canbe employed.

Press bars 60, 70 and backing bars 80, 90, 100 are formed of a crossbeam 50 and a contact surface 56, wherein the contact surface is usuallya separate material than the cross beam. Cross beam 50 is a generallyrigid member sufficient to remain substantially undeformed (undeflected)along the operable length of the bar during operating conditions. Forexample, deflections of less than approximately 0.005 inches andtypically less than 0.003 inches along a 5 foot length of cross beam 50have been found satisfactory. Aluminum or steel has been found to be asatisfactory material for cross beams 50. Press bars 60, 70 and backingbars 80, 90, and 100 are sized to extend substantially the entire lengthof score line 26, and provide a continuous line of contact with ribbon20 along the score line.

The material forming contact surface 56 is a polymeric material such asa thermoplastic, thermoset or thermoplastic elastomer. Silicone having ahardness of approximately 60 Shore A plus or minus 10, has been found asatisfactory material. However, it is understood that depending upon theconfiguration of the apparatus, and the desired characteristics of theinterface between the respective bar and ribbon 20, the performancecharacteristics of the material forming contact surface 56 can bechanged. For example, upstream backing bar 80, when also functioning asthe scoring bar, may be formed of a harder surface than upstream pressbar 60.

Contact surface 56 can be connected to cross beam 50 by any of a varietyof mechanisms including adhesives, bonding or friction fit. As shown inthe FIGS. 6-9 and called out in FIGS. 10 a-10 d, cross beam 50 includesa channel 51 having a given cross section, and contact surface 56includes a corresponding locking tab 57 for engaging the channel.Although contact surface 56 is set forth as a member defining a surfaceas well as locking tab 57, it is contemplated the contact surface can belimited to a surface layer or film disposed on a substrate, wherein thesubstrate performs the function of the locking tab.

Referring to FIGS. 10 a-10 d, contact surface 56 can define any of avariety of interfaces with ribbon 20. For example, contact surface 56can define an inclined plane with respect to the surface of ribbon 20.In such configuration, as contact surface 56 engages ribbon 20,increased force is exerted along predetermined positions of the contactsurface. Contact surface 56 extends along the length of score line 26and contact ribbon 20 along an appropriate ½″ length of the ribbon.

Each of the upstream press bar 60, upstream backing bar 80, downstreampress bar 70, secondary upstream backing bar 90 and downstream backingbar 100 travel at a velocity vector substantially equal to the velocityvector V of ribbon 20. Press bars 60, 70 and backing bars 80, 90 and 100are carried by a carriage 120 for translation with the appropriatevelocity vector matching ribbon 20, as is known in the art.

For purposes of description, press bars 60, 70 and backing bars 80, 90,100 are described in terms of travel on common carriage 120. Carriage120 can be movable relative to a rail 124, wherein the movement of thecarriage can be imparted by any of a variety of mechanisms includingmagnetic, mechanical, or electromechanical, such as motors, gears,and/or rack and pinion. Thus, press bars 60, 70 and backing bars 80, 90,100 can be moved with the same velocity vector V of ribbon 20, and uponcontact with the ribbon maintain contact at a specific location on theribbon.

In certain configurations, upstream backing bar 80 also functions as ascore-nosing bar, without deviating from the present apparatus. That is,as seen in FIGS. 6-9, upstream backing bar 80 contacts second side 34 ofribbon 20 upstream of score line 26, as well as contacting the secondside of the ribbon opposite the score line (or the intended position ofthe score line).

As shown schematically in FIGS. 3-5, upstream press bar 60 is connectedto carriage 120 for engaging first side 32 of ribbon 20 and the upstreambacking bar is connected to the carriage for engaging second side 34 ofthe ribbon to restrain the ribbon.

Upstream press bar 60 and upstream backing bar 80 can contact theopposing sides of ribbon 20 in an opposite, an offset, or overlappingrelation. In the “opposite” relation seen in FIG. 4, upstream press bar60 and upstream backing bar 80 engage ribbon 20 at a common distancefrom root 14. For ribbon 20 having a vertical velocity vector V, theopposite contact occurs at a given height (vertical position along theribbon). In the “offset” relation seen in FIG. 3, upstream press bar 60and upstream backing bar 80 engage ribbon 20 at different distances fromroot 14. That is, there is no common length of the ribbon contacted onfirst side 32 by upstream press bar 60 and second side 34 by upstreambacking bar 80. In the “overlapping” relation seen in FIG. 5, a portionof each of the upstream press bar 60 and upstream backing bar 80 contactthe respective side of ribbon 20 along a common length of the ribbon.For example, in the overlapping relation, if each of the upstream pressbar 60 and upstream backing bar 80 has a ½″ contact with the ribbonapproximately ¼″ of the contact of each of the upstream press bar andthe upstream backing bar can overlap along a common ¼″ length of theribbon to restrain the ribbon.

Upstream press bar 60 and upstream backing bar 80 can be controlled tosimultaneously or sequentially contact the respective sides of ribbon20. However, it is advantageous to have both upstream press bar 60 andupstream backing bar 80 contacting ribbon 20, during and afterseparation of pane 24.

Upstream press bar 60 and upstream backing bar 80 can be movablyconnected to carriage 120 for movement between a retracted non-ribboncontacting position and an extended ribbon contacting position. Any of avariety of mechanisms can be used for moving upstream press bar 60 andupstream backing bar 80 relative to carriage 120. For example, cams cancouple bars 60, 80 to carriage 120. Alternatively, mechanical actuatorssuch as rack and pinion or threaded engagements, hydraulic or pneumaticpistons or cylinders can be used.

Thus, upstream press bar 60 and upstream backing bar 80 can moverelative to carriage 120 between a retracted non-contacting position andan extended ribbon contacting position. Alternatively, upstream pressbar 60 and upstream backing bar 80 can be fixed with respect to carriage120, and the carriage can be moved relative to rail 124 to selectivelyengage the bars with ribbon 20.

In selected configurations, as seen in FIGS. 6 a-6 d, upstream press bar60 and downstream press bar 70 can be incorporated into a single crossbeam 50, and thus move in concert. Alternatively, upstream press bar 60and downstream press bar 80 can be tied to a common carrier or yoke.Conversely, upstream press bar 60 and downstream press bar 70 can beindependently controlled (operated) to provide sequential or independentcontact with ribbon 20 as seen in FIGS. 7-9.

Similarly, upstream backing bar 80, secondary upstream backing bar 90and downstream backing bar 100 can be carried by single cross beam 50 tomove in concert between the retracted position and the extendedposition. Alternatively, each of the upstream backing bar 80, secondaryupstream backing bar 90, and downstream backing bar 100 can be carriedby an independent and independently actuated cross beam 50, as desired.

In one configuration, press bars 60, 70 and scoring assembly 130 contactfirst side 32 of ribbon 20 within an approximate 3 inch length of theribbon. Thus, for those configurations in which score line 26 is equallyspaced from the upstream press bar and downstream press bar, the barsare within approximately 1.5 inches from the score line.

Similarly, upstream backing bar 80, secondary upstream backing bar 90and downstream backing bar 100 span approximately 3 inches or less alongthe length of the ribbon 20. In certain configurations, upstream pressbar 60 can be within 2 inches or less than 1 inch from score line 26.Downstream press bar 70 can be less than 3 inches to less thanapproximately 1 inch from score line 26. In one configuration bars 60,70 are located within a 37 mm length of ribbon 20.

Load sensors or force sensors, such as piezoelectric or spring biasedsensors, can be connected between respective bar 60, 70, 80, 90, 100 andcarriage 120 to measure the load on the respective bar. The sensors areconnected to a central controller so that the desired loads can bedetermined, monitored and controlled.

A scoring assembly 130 is used to selectively form score line 26 infirst side 32 of ribbon 20. Scoring assembly 130 can travel with one orboth upstream press bar 60 and upstream backing bar 80. For purposes ofdescription, scoring assembly 130 is set forth as carried by carriage120. Thus, scoring assembly 130 will travel along the direction oftravel of ribbon 20, at a velocity vector matching the ribbon. Asscoring assembly 130 translates along the same direction of travel asribbon 20, score line 26 can be formed to extend transverse to thedirection of travel of the ribbon.

Scoring assembly 130 can be any of a variety of configurations wellknown in the glass scribing art, including but not limited to lasers,wheels, or points.

For those configurations of scoring assembly 130 that require contactwith ribbon 20 to form score line 26, the scoring assembly is alsomovable between a retracted non-contacting position and an extendedribbon contacting position.

Typically, scoring assembly 130 cooperates with upstream backing bar 80to form the score line 26 along first surface 32 of ribbon 20, such thatthe upstream backing bar also functions as a scoring bar opposite thecontact of scoring assembly 130 and ribbon 20.

Score line 26 extends across a substantial width of ribbon 20. For theconfiguration of ribbon 20 having beads 36, score line 26 extendssubstantially the entire distance between the beads. Thus, the scoreline can extend from approximately 70% of the width of ribbon 20 to 100%of the width. Typically, score line 26 has a depth of approximately 10%of the thickness of ribbon 20. The actual depth of score line 26 dependsin part upon scoring parameters such as scoring pressure, the geometryof the scoring assembly, the thickness of the ribbon, the material ofthe ribbon, and the characteristics of glass fabrication apparatus 10.For representative ribbon thickness, score line 26 can have a depthranging from approximately 70 microns to approximately 130 microns.

A pane engaging assembly 140 is employed to capture ribbon 20 downstreamof score line 26 and control removal of pane 24 upon separation fromribbon 20. A representative pane engaging assembly and associatedtransporter are described in U.S. Pat. No. 6,616,025, herein expresslyincorporated by reference.

The pane engaging assembly 140 includes pane engaging members 142, suchas soft vacuum suction cups. It is understood other devices for engagingpane 24, such as clamps or fingers that engage the lateral edge of theribbon (pane) can be used. The number of pane engaging members 142 canbe varied in response to the size, thickness and weight of pane 24.

Pane engaging assembly 140 can engage ribbon 20 either before or afterscore line 26 has been formed. In addition, pane engaging assembly 140can include a drop cylinder for imparting a vertical movement of pane 24from newly formed terminal end 22 of ribbon 20.

With respect to separation of pane 24 from ribbon 20 along score line26, a combination of the bars contacting the ribbon is employed topropagate a crack along the score line. Any of a variety of combinationof contacts between the bars and ribbon 20 can be employed to separatepane 24. For example, it is contemplated downstream press bar 70 can beemployed to provide a breaking function (function as a breaking bar).Alternatively, both upstream press bar 60 and downstream press bar 70can act cooperatively against ribbon 20 to induce separation along scoreline 26.

Generally, upper press bar 60 and upper backing bar 80 restrain aportion of ribbon 20 therebetween. By restraining the portion of ribbon20, deviation of the ribbon from the gravity induced velocity vector isreduced. In addition, restraining a portion of ribbon 20 upstream ofscore line 26 allows the dampening characteristics of contact surfaces56 to reduce the transmission of disturbances (energy) into the ribbon.

In contrast to prior systems, a localized bending is applied about scoreline 26, wherein the localized bending is sufficient to propagate acrack along the score line.

The contact of upstream press bar 60, upstream backing bar 80 (andsecondary upstream backing bar 100) during and immediately afterseparation of pane 24 from ribbon 20, function to dampen thetransmission of mechanical vibrations upstream in the ribbon. Thus,movement of ribbon 20 above score line 26 is thus reduced during theseparation process. The continued contact between upstream backing bar80 and upstream press bar 60 with ribbon 20 after separation absorbs aportion of the energy imparted by the separation process, and thusreduces the amount of disturbance that can migrate upstream in theribbon.

In addition, by locating continuous lines of contact from the respectivebars proximal to score line 26, such as within 3 inches (7.6 cm), a moreuniform energy distribution is applied across ribbon 20 in the locationof the score line, thereby improving separation characteristics of pane24. It is believed accuracy of the separation line with respect to scoreline 26 is increased as bars 60, 80 (and 70) provide a more uniformstress along the length of the score line. This allows the position ofscore line 26 to vary by as much as 1 mm without sacrificing efficiencyof the separation process.

Press bars 60, 70 and backing bars 80, 90, 100 can also be employed tosubstantially maintain (or create) a substantially planar configurationof the ribbon in the area of score line 26 before or after formation ofthe score line.

For purposes of illustration, four different specific arrangements ofupper press bar 60 and upper backing bar 80 contacting ribbon 20 are setforth in detail.

Referring to FIGS. 6 a-6 d, a first configuration of the assembly isemployed to separate pane 24 from terminal end 22 of ribbon 20. As seenin FIG. 6 a, upstream backing bar 80 is brought to contact second side34 of ribbon 20 and scoring assembly 130 is drawn across at least aportion of the width of the ribbon to form score line 26. Pane engagingassembly 140 is shown engaged with ribbon 20, prior to formation ofscore line 26. However, it is understood that the pane engaging assemblycan engage ribbon 20 after formation of score line 26. Referring to FIG.6 b, upstream backing bar 80 functions as the score-nosing bar or anvil.Although scoring assembly 130 is shown as returning to an upstreamposition relative to upstream press bar 60, it is understood the scoringassembly can move laterally (horizontally in FIG. 6 b) between a scoringposition and a non scoring position. Subsequently to the formation ofscore line 26, upstream press bar 60 and downstream press bar 70 arebrought into contact with first side 32 of ribbon 20 to locate scoreline 26 intermediate the upstream press bar and the downstream press barand restrain a portion of the ribbon upstream of score line 26 by thecontact of upstream backing bar 80 and the upstream press bar with theribbon. Upstream press bar 60 and upstream backing bar 80 can be sizedand located to contact ribbon 20 and either an offset, overlapping oropposite relation. Further, although upstream press bar 60 anddownstream press bar 70 are shown as incorporated into single crossbeam50, each press bar is called out as an individual structure. That is,each of the upstream press bar 60 and downstream press bar 70 canencompass respective contact surface 56 and a portion of the commoncrossbeam 50.

In FIG. 6 c, upstream press bar 60 and downstream press bar 70 are urgedtowards upstream backing bar 80, while pane engaging assembly 140 drawsthe ribbon from the vertical path and ribbon 20 is separated along scoreline 26. It is understood, upstream press bar 60 can contact ribbon 20simultaneous with contact of downstream press bar 70, or prior tocontact of the downstream press bar with the ribbon. In either scenario,a portion of ribbon 20 is restrained between upstream press bar 60 and aportion of upstream backing bar 80, such that the ribbon remainsrestrained upstream of the separation line, after separation of theribbon.

In FIG. 6 d, upstream press bar 60, downstream press bar 70, upstreambacking bar 80, and scoring assembly 130 are realigned with ribbon 20for forming subsequent pane 24.

It is also noted that upon upstream press bar 60 and upstream backingbar 80 having at least a slight overlapping relation along the length ofribbon 20, the application of a bending moment to upstream ribbon 20 isreduced. The amount of overlap of upstream press bar 60 and upstreambacking bar 80 is at least partially determined by the type andthickness of material forming ribbon 20.

Referring to FIG. 7 a, upstream backing bar 80 and at least upstreampress bar 60 are brought into contact with ribbon 20, prior to formingscore line 26 (and thus restrain the ribbon). Again, pane engagingassembly 140 is engaged with ribbon 20 prior to formation of the scoreline. However, it is understood that pane engaging assembly 140 canengage ribbon 20 after formation of score line 26. In FIG. 7 b, scoringassembly 130 is brought into contact with first side 32 of ribbon 20 andbears against a portion of backing bar 80 to form score line 26. In FIG.7 c, scoring assembly 130 is retracted. In FIG. 7 d, the downstreampress bar 70 is urged against first side 32 of ribbon 20 to separatepane 24 from the ribbon. In FIG. 7 e, downstream press bar 70 andscoring assembly 130 are in the retracted position, while upstreambacking bar 80 and upstream press bar 60 remain in contact with ribbon20, thereby dampening the transmission of any disturbance resulting fromthe separation of pane 24 from the ribbon. In FIG. 7 f, the bars arereturned to an initial position for separating a subsequent pane 24 fromribbon 20.

Again, the relation of upstream backing bar 80 and upstream press bar 60(and downstream press bar 70) can be offset, opposite or overlapping.Although upstream press bar 60 and downstream press bar 70 can besimultaneously moved into contact with first side 32 of ribbon 20, andsimultaneously moved after formation of score line 26 to separate pane24, it is anticipated that independently moving the downstream press barto initiate crack propagation along the score line is advantageous.

Referring to FIG. 8 a, secondary upstream backing bar 90 and upstreampress bar 80 are initially brought into contact with second side 34 andfirst side 32 of ribbon 20 respectively. In addition, downstream pressbar 70 can optionally contact the first side of ribbon 20 to furtherstabilize and control the ribbon. In FIG. 8 b, upstream backing bar 80and scoring assembly 130 are brought into contact with ribbon 20 to formscore line 26 intermediate upstream press bar 60 and downstream pressbar 70. A portion of upstream backing bar 80 contacts second side 34 ofribbon 20 upstream of score line 26. Thus, ribbon 20 is restrainedupstream of score line 26 by a portion of upstream backing bar 80 andsecondary upstream backing bar 90 on second side 34 of the ribbon andupstream press bar 60 on first side 32 of the ribbon. Pane engagingassembly 140 engages ribbon 20. In FIG. 8 c, scoring assembly 130 isretracted after score line 26 is formed. In FIG. 8 d, downstream pressbar 70 is urged further against first side 32 of ribbon 20 causing pane24 to separate from the ribbon. In FIG. 8 e, separated pane 24 isremoved by pane engaging assembly 140, and newly formed terminal end 22of the ribbon is restrained by a portion of upstream backing bar 80,secondary upstream backing bar 100 and upstream press bar 60. In FIG. 8f, the bars are returned to a ready position to begin the sequence forseparating a subsequent pane 24 from ribbon 20.

With respect to the series of FIG. 9, the configuration is selected toreduce premature unintended crack propagation along score line 26.Generally, the configuration of FIG. 9 induces a local compression infirst side 32 of ribbon 20 adjacent the score line 26. This localcompressive force reduces the tendency of crack propagation along scoreline 26. The bar configuration shown in FIG. 9, provides for the initialcompression and a subsequent tension across score line 26, and hencecontrolled crack propagation.

In the series of FIG. 9, pane engaging assembly 140 is employed tocapture pane 24 and remove the pane from descending ribbon 20. As seenin FIG. 9 a, upstream backing bar 80, secondary upstream backing bar 90and downstream backing bar 100 are mounted in a common crossbeam 50,wherein the secondary upstream backing bar and the downstream backingbar project a greater distance than the upstream backing bar. That is,upstream backing bar 80 is recessed relative to secondary upstreambacking bar 90 and downstream backing bar 100, so that second side 34 ofribbon 20 initially contacts the secondary upstream backing bar and thedownstream backing bar. Although secondary upstream backing bar 90 anddownstream backing bar 100 can be of a softer, more easily compressiblematerial than upstream backing bar 80, as upstream press bar 60 contactsfirst side 32 of ribbon 20, a slight bow is imposed in the ribbon suchthat a local compressive force is created in the intended area of scoreline 26.

Although upstream backing bar 80 can be separately controlled fromsecondary upstream backing bar 90 and downstream backing bar 100, theapparatus is simplified by mounting upstream backing bar 80, secondaryupstream backing bar 90 and downstream backing bar 100 to a commoncrossbeam 50, and employing different size contact surfaces 56.

Referring to FIG. 9 b, scoring assembly 130 then forms score line 26 inthe locally compressed first side 32 of ribbon 20. Subsequently, as seenin FIG. 9 c, scoring assembly 130 is retracted, and downstream press bar70 is urged against the first side of ribbon 20 with sufficient force togenerate a localized tension in the first side of the ribbon in the areaof score line 26. Pane 24 then separates from ribbon 20 as seen in FIG.9 d while ribbon 20 remains restrained between secondary upstreambacking bar 90 and upstream backing bar 80 on second side 34, andupstream press bar 60 on the first side. Pane engaging assembly 140removes pane 24 in FIG. 9 d. Referring to FIG. 9 f, the bars and scoringassembly 130 are returned to the ready position for separating asubsequent pane 24.

The present configurations thus provide for an opposed contact of ribbon20 upstream of score line 26 (or score line location), wherein theupstream opposed contact can be in an offset, opposite or overlappingrelation of upstream press bar 60 and upstream backing bar 80.

Subsequently, crack propagation is induced along score line 26 and pane24 is separated from ribbon 20.

The upstream contact with ribbon 20 is maintained during and after theseparation of pane 24, thereby reducing the introduction of disturbancesthat can migrate up the ribbon.

In certain configurations, the upstream restraining of ribbon 20 can besubsequent to formation of score line 26 and substantially simultaneouswith the separating of the ribbon along the score line. In furtherconfigurations, the upstream restraining of ribbon 20 precedes theformation of score line 26.

While the invention has been described in conjunction with specificexemplary embodiments thereof, it is evident that many alternatives,modifications, and variations will be apparent to those skilled in theart in light of the foregoing description. Accordingly, the presentinvention is intended to embrace all such alternatives, modifications,and variations as fall within the spirit and broad scope of the appendedclaims.

1-16. (canceled)
 17. An apparatus for separating a pane from a movingribbon of brittle material traveling in a moving direction with avelocity vector V, the moving ribbon having a first side, a second sideand a width direction substantially orthogonal to the moving direction,the apparatus comprising: a scoring assembly for forming a score line inthe first side of the moving ribbon of brittle material along the widthdirection, the scoring assembly configured to move at a velocity vectorsubstantially matching the velocity vector V; a first press barsextending along the width direction and configured to contact the firstsides upstream of a score line at a velocity vector substantiallymatching the velocity vector V; a first backing bar extending along thewidth direction and configured to contact the second side alongsubstantially the entire width of the moving ribbon of brittle materialat a velocity vector substantially matching the velocity vector V; and asecond press bar extending along the width direction configured tocontact the first side downstream of the score line at a velocity vectorsubstantially matching the velocity vector V.
 18. The apparatus of claim17, wherein the first press bar and the first backing bar are in anoffset relation relative to the draw direction.
 19. The apparatus ofclaim 17, wherein each of the first press bar and the first backing barcomprise a cross beam and a polymeric contact surface.
 20. (canceled)21. The apparatus according to claim 19, wherein the polymeric contactsurface of the first press bar comprises silicone having a Shore Ahardness of 60±10.
 22. The apparatus according to claim 19, wherein ahardness of the polymeric contact surface of the first backing bar isharder than a hardness of the polymeric hardness of the first press bar.22. The apparatus according to claim 17, wherein the first press bar,the second press bar and the first backing bar are connected to acarriage assembly.
 23. The apparatus according to claim 17, wherein thefirst press bar and the first backing bar are movable between aretracted non-contacting position and an extended contacting positionrelative to the moving ribbon of brittle material.
 24. The apparatusaccording to claim 17, wherein the first press bar and the first backingbar overlap in the width direction.
 25. The apparatus according to claim22, further comprising a load sensor connected between the carriage andat least one of the respective first press bar, second press bar orfirst backing bar.